Automated bricklaying device

ABSTRACT

1. AN AUTOMATED BRICKLAYING DEVICE FOR LAYING OUT THE BRICK LINING OF A VESSEL, THE DEVICE COMPRISING: A DELIVERY MEANS FOR DELIVERING A SERIES OF BRICKS IN TURN TO THE CIRCUMFERENCE OF THE VESSEL TO BE SET AS THE LINING THEREOF; A BRICK POSITIONING MEANS ASSOCIATED WITH SAID DELIVERY MEANS FOR BOTH CIRCUMFERENTIALLY AND LATERALLY POSITIONING AND FIRMLY SETTING BRICK IN TURN IN THE LINING AS IT IS DELIVERED TO THE CIRCUMFERENCE OF THE VESSEL; A SUPPORTING MEANS FOR SUPPORTING SAID DELIVERY MEANS AND SAID BRICK POSITIONING MEANS INSIDE THE VESSEL AND FOR PERMITTING, OF SAID DELIVERY MEANS AND SAID BRICK POSITIONING MEANS, LONGITUDINAL MOVEMENT ALONG, RECIPROCAL LATERAL MOVEMENT RELATIVE TO AND REVOLUTIONAL MOVEMENT ABOUT AN AXIS THEREOF POSITIONED WITHIN AND SUBSTANTIALLY PARALLEL TO THE AXIS OF THE VESSEL TO BE LINED; AN OPERATING MEANS FOR MOVING SAID DELIVERY MEANS AND SAID BRICK POSITIONING MEANS LONGITUDINALLY ALONG, LATERALLY RELATIVE TO AND REVOLUTIONALLY ABOUT SAID AXIS OF SAID SUPPORT MEANS SO AS TO POSITION SAID DELIVERY MEANS AND SAID BRICK POSITIONING MEANS RELATIVE TO THE CIRCUMFERENCE OF THE VESSEL; AND (A) AUTOMATIC CONTROL MEANS FOR CONTROLLABLY OPERATING SAID OPERATING MEANS (AFTER A BRICK HAS BEEN POSITIONED IN PLACE IN THE LINING FOR PROPERLY POSITIONING SAID DELIVERY MEANS AND SAID BRICK POSITIONING MEANS) INCLUDING MEANS FOR STOPPING SAID OPERATING MEANS WHEN SAID DELIVERY MEANS AND SAID BRICK POSITIONING MEANS ARE PROPERLY POSITIONED FOR THE PLACEMENT OF THE NEXT SUCCEEDING BRICK IN THE LINING, SAID MEANS BEING RESPONSIVE TO THE POSITION OF THE LASTLY LAID BRICK IN THE LINING.

Jan. 21, 1975 m WILLIAMSON 31', Re. 28.305

AUTOMATED BHICKLAYING DEVICE original Filed may 15. i97 l1 Sheets-Sheeti JUL 21, 1975 R, WILLIAMSON ET AL 23305 AUTOMATED BRICKLAYING DEVICEOriginal Filed May L5, 1972 ll Sheets-Sheet 2 1975 R. E, WILLIAMSON ETALRt 3 AU OMTED BRICKLAYINC DEVICE 11 Sheets--Shaet flrigirml Filed May15, 1972 m m\m Jan. 21, 1975 R, WILLIAMSON ETAL 23305 AUTQMATEUBRlCKLAYINC' DEVICE ll Sheets-Sheet Original Filed May 15, 1972 vON ONQON NON mON OON w\N SN N- V2 m:

m2 3! mm: m2 Iv m9 [i A- v9 1 :2 omK mt@ Yi 09 m9 v9 NE NE Jan. 21,WILLIAMSON E L Re. 28,305

AUTOMATED BRICKLAYING DEVICE Original Filed May 15, 1972 FIG.

11 5heets-Sheet L Jan.2l,l975

R.EJWHJJAMSON ETAL AUTOMATED BRICKLAYING DEVICE 11 SheetS-Sheet 5Original Filed May 15, 1972 Nvm mm 1mm mmm mmm 0mm 0mm \vm 5N mOn mm vmJan- 21. 1975 a, WILLIAMSON ETAL Re. 28.

AUTONTED BRICKLAYING DEVICE ll Sheets-8heet Original Filed May 15, 1972FIG. 8A

FIG. 8B

Jan. 21, 1975 R W|LL|AM$ON E-TAL Re. 28,305

ll Sheets-$12591. B

264 236 298 290 29! 23s 2 e s 6 230 FIG. 10

324 ,522 L 318 Hz 316 320 92 346 41 H4 92 Jan. 21, R. E. wlLUAMSON ETALRe.

AUTOMATED BRICKLAYING DEVICE Original Filed May 15, 1972 ll Sheets-Sh6et9 294 272 288 284 300 274 292 278 553 276 29 239 514 3:2 302 236 26 282238 i 291 262 290 240 254 247|264 306 Fl 6. H

256 kzoo FIG. I2

Jan. R. E. LU N T Re. 28,305

AUTOMATED BRICKLAYING DEVICE Original Filed May 15, 1072 ll Sheets-Sheet10 N? 31 6C 5 vwvKVAm o? v TQM. 3L5. N? mm? mm: So Ev wmv omv ow mmwfimm NE zsom o2 ovv Sv vow we g nu wow WA M 0 am; mov 0E 02 DOV 1975 R.WILLIAMSON ETAL ,3

AUTOMATED ERICKLAYING DEVICE Original Filed May 15, 1972 ll SheetS Sheet11 United States Patent O 28,305 AUTOMATED BRICKLAYING DEVICE RonaldEugene Williamson, Hammondsville, and Sidney Clark Porter, Jr., EastLiverpool, Ohio, and Kenneth Frederic Shutting, Coraopolis, Pa.,assignors to Combustion Engineering, Inc., Windsor, Conn.

Original No. 3,757,484, dated Sept. 11, 1973, Ser. No. 253,546, May 15,1972. Application for reissue May 3, 1974, Ser. No. 466,566

Int. Cl. B65g 37/ E04g 21/22 U.S. Cl. 52-749 34 Claims Matter enclosedin heavy brackets appears in the original patent but forms no part ofthis reissue specification; matter printed in italics indicates theadditions made by reissue.

ABSTRACT OF THE DISCLOSURE An automated bricklaying device for layingout the refractory brick lining of a metal pouring ladle having anupright frame means mounted on a mounting means for traversing theinterior circumference of the ladle. A platform means, which has adelivery means mounted theeon for reciprocal lateral movement, iscarried by the upright frame means for substantially vertical movementwithin the ladle. The delivery means continuously delivers a series ofrefractory bricks in turn to the circumference of the ladle to be set asthe lining thereof. A positioning and indexing means properly positionseach brick in turn in the lining as it is delivered from the deliverymeans. The positioning and indexing means additionally serves to indexthe upright frame means to a proper position .for placement of the nextsucceeding brick in the lining.

A vertical guidance means on the delivery means provides verticalelevational control of the platform means relative to the built uplining.

BACKGROUND OF THE INVENTION In the making of steel a ladle is requiredfor receiving molten steel from the steel-making furnace, the ladleserving to transport the steel from the furnace to the area in whichingots or castings are made. These ladles must have some means toprevent the molten steel from penetrating to the outer metal sheath ofthe ladle and as such require a refractory lining. The refractory liningmust exhibit the characteristics of being readily adaptable to conformto the shape of the ladle and the ability to withstand widelyfluctuating temperatures and erosive action of the molten steel. Sincethe ladle is moved and tilted about its supporting axis, the lining mustbe so cohesive to remain in place during movement, yet be capable ofbeing easily removed for repair or replacement.

Ladle linings are presently formed by building up individual refractoryblocks in a close fitting pattern. The blocks generally used are curvedconvexly at one end and concavely at the other, with the chordal planethrough the cylindrically curved ends of each form of block not havingthe same angular relation. By this construction a standard refractoryblock may be used to build a lining for ladles of varying sizes andvarying shapes. This arrangement is shown in US. Pat. No. 3,140,333 toW. T. Tredennick.

In forming the ladle lining, the refractory blocks have been placedwithin the ladle by hand by unskilled laborers generally taking from16-64 manhours per ladle. Even though the blocks are uniform so thatlittle skill is involved, this use of manual labor adds considerably tothe overall cost of steel manufacture. This expense is compounded by thefact that the ladle lining will only last Re. 28,305 Reissued Jan. 21,I975 through approximately 20 charges from the steel-making furnacebefore the lining must be replaced. This requires that the ladle betaken out of service for lining replacement after only several daysoperation.

SUMMARY OF THE INVENTION There is herein provided an apparatus forautomating the laying of refractory bricks within a metal pouring ladleto serve as the working lining thereof, thereby reducing the timenecessary for relining as well as the cost. A delivery means, fordelivering a series of refractory bricks in turn to the circumference ofthe ladle to be set as the lining thereof, is supported inside the ladleby a support means. The support means permits of the delivery meanslongitudinal movement along, reciprocal lateral movement relative to,and revolutional movement about an axis thereof positioned within andsubstantially parallel to the axis of the ladle to be lined. A brickpositioning means is associated with the delivery means and is providedfor positioning and firmly setting each brick in turn in the lining asit is delivered to the circumference of the ladle. The delivery meansand the brick positioning means are moved longitudinally along,laterally relative to and [revolutionary] revolirtionally about the axisof the sup port means by an operating means so as to position thedelivery means and brick positioning means relative to the circumferenceof the ladle. A control means controllably operates this operating meansafter a brick has been positioned in place in the lining so as toproperly position the delivery means and brick positioning means for theplacement of the next succeeding brick in the lining.

With such an apparatus, a ladle may be lined in 34 hours. Also, only oneman is required to operate the bricklaying device.

Although this automated bricklaying device was developed for use inlining metal pouring ladles, it will be apparent from the descriptionhereinbelow that the device is readily adaptable to reline any type ofvessel in which relining is periodically required.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevation view of theautomated bricklaying device according to the present inventionpositioned within the ladle shell;

FIG. 2 is a front elevation view, partly in section, taken along line 22of FIG. 1 with a portion thereof removed;

FIG. 3 is a top view of the automated bricklaying device taken alongline 3-3 of FIG. 1;

FIG. 4 is an elevation view, partly in section, taken along line 4-4 ofFIG. 3;

FIG. 5 is a detailed section view of the conveyor indexing mechanismaccording to the present invention taken along line 5-5 of FIG. 3;

FIG. 6 is a perspective view of the brick gripper according to thepresent invention;

FIG. 7 is an elevation view of a portion of the conveyor assembly takenalong line 7-7 of FIG. 11;

FIGS. 8A and 8B are diagrammatic representations showing the operationof the brick gripper according to the present invention;

FIG. 9 is a front elevation view of the conveyor assembly taken alongline 9-9 of FIG. 10;

FIGS. 10, 11 and 12 are detailed plan views of a portion of the conveyorassembly showing the sequential operations according to the presentinvention in laying a brick in the lining of the ladle;

FIG. 13 is a detailed view showing the actuation of a limit switchutilized in the control of the present invention;

FIGS. 14A and 14B are diagrammatic representations of the control systemaccording to the present invention.

3 DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings,FIGS. 1 and 2 show an automated bricklaying device positioned within ametal pouring ladle 22. The ladle 22 is comprised of a steel shell 24with a safety lining 26 forming the interior thereof. Within the safetylining 26 is a working lining 28 which is periodically damaged anderoded during the steelmaking process and needs to be replaced. It isthe replacement of this working lining 28 to which the particularbricklaying device 20 of this invention is concerned.

The automated bricklaying machine is comprised of three separateassemblies such that it may be installed and removed from the ladle inthree pieces or sections, or alternatively it may be installed orremoved as a unit. These three assemblies are the support assembly 30,the elevator frame assembly 64, and the carriage assembly 90. Thesupport assembly 30, as depicted in FIGS. 1 and 2, is a turntablemechanism comprised of a lower platen 32 supported on the floor of theladle 22 by means of leveling screws mounted in flanges 38 spaced aboutthe periphery of the platen 32 and an upper platen 34 having a centraldownwardly extending shaft 36 journaled in bearing 35 on the lowerplaten 32. The upper platen 34 is supported from the lower platen 32 forrotation relative thereto about the shaft 36 by a plurality of rollers44 intermittently spaced about and journaled in an upright ring 42positioned at the periphery of the lower platen 32. An annular gear ring46 having outwardly extending gear teeth is centrally located on thelower platen by an inner locating ring 48 for engaging a pinion gear 50having a shaft 52 journaled in a bearing 54 of the upper platen 34. Asprocket 56 is rigidly fixed to the shaft 52 above the platen 34 and isconnected to a rotary air motor 60 by a chain 58 for rotating the piniongear 50 which in turn will rotate the upper platen 34 relative to thelower platen 32.

The elevator frame assembly 64 is comprised of two spaced T-shapedstandards 65 formed by joining together a rectangular beam 66 and a flatplate 67 as shown in FIGS. 1, 2 and 3. Each of the standards 65 hasintegrally attached thereto at its lower end a connecting couple 68whose inner surface conforms identically to the outer surface of lugs 62provided on the platen 34, the lugs 62 serving to support the elevatorframe assembly at an angle conforming to the slope of the ladle wall 24.A pin 69 passes through the lugs 62 and the connecting bases 68 to holdthe standards in place. Standards 65 are interconnected and held inspaced relation by a tie bar 70 at the bottom, an X-brace 72 near thetop and a tie bar support at the top, the support 80 having liftingholes 88 for introducing into or removing from the ladle 22, either theelevator frame assembly 64 or the entire bricklaying device 20. A hoistmotor support 76 integrally attached to the standards 65 extendslaterally outward from the elevator frame assembly and supports a rotaryair actuated hoist motor 78 thereon. A cable 86 extending from the hoistmotor 78 passes over sheaves 81 separated by sheave spacers 83 of theupper and lower hoist blocks 82 and 84, the upper hoist block 82 beingsupported from the tie bar support 80 and the lower hoist block 84 beingsupported by the cable 86. Actuation of the hoist air motor 78 willeffectuate either a lowering or raising of the lower hoist block 84.

The carriage platform assembly 90 is carried by the elevator frameassembly 64 in such a manner so as to be vertically movable Within theladle 22. The carriage assembly 90 has horizontal base members 94supporting a platform 92. Two carriage upright supports 96 extend upwardfrom the base members 94 inclined relative to the plate at an anglesubstantially equal to the incline angle of the ladle and elevator frameassembly 64. The upper portion of the uprights 96 are interconnected bycross support 98 having integrally attached thereto a downwardlyextending pin 108. As best seen in FIG. 4, the cross support 98 and thusthe carriage assembly 90, is supported from the elevator frame assembly64 by the lower hoist block extension [84] 85, the pin 108 passingthrough a hole in the extension [84] and being retained in place by acotter pin 110 extending through a transverse hole in the pin 108. Thismanner of supporting the carriage assembly is advantageous in that thelower hoist block 84 remains coupled to the elevator frame assembly 64upon removal of the carriage assembly therefrom.

A plurality of rollers 100, 104 and 106 are rotatably mounted from theupright supports 96 so that the carriage platform assembly 90 will beguided in its vertical movement within the ladle 22 by the elevatorframe assembly 64. The upper set of rollers 100 ride on the rear surfaceof the plate 67 of the elevator standard 65 and are journaled in plates102 extending outward from the uprights 96 on either side of thestandards 65 while the lower rollers 106 are journaled in the uprights96 to ride along the front surface of the plate 67. The combination ofthese two sets of rollers 100, 106 provides the necessary stability toinsure that the carriage assembly 90 remains in position as it is movedup and down the standards 65. Lateral stability is provided for thecarriage assembly 90 by the rollers 104 which pass along the outsideedges of the flat plate 67. There are two rollers 104 positioned at theupper portion of the uprights 96 and two positioned at the lowerportion.

A boom mechanism 118 is supported from the cross support 98 for liftingbricks 144 from the pallets of bricks on the platform 92 and placingthem on a delivery means or conveyor assembly 146 to be describedhereinbelow. A support member 120 attached to the cross support member98 carries pivot pin 126 to which is mounted for pivotal movement in ahorizontal plane a first beam 122. A second beam 124 is pivotallyconnected by pin 128 to the first beam 122. A hoist motor 130 isattached to the distal end of the second beam 124 and a cable 131extends downward therefrom to carry ice tong grippers 132.

The ice tong grippers are comprised of two hollow tubes 134 into whichextend bars 136- having gripping surfaces 138 at the distal ends. thetubes 134 being pivotally connected by pin 140. Screws 137 tightly holdthe bars 136 in place within the tubes 134. The cable 131 is attached tolugs 142 of the tubes 134 such that upon actuation of the air hoist 130to retract the cable 131, the hollow tubes 134 pivot about pin to grip aseries of bricks 144, the bricks then being lifted from the pallet andplaced on the conveyor assembly 146.

As best seen in FIGS. 2, 3, 4 and 9, the platform 92 has been cut awaybetween the horizontal support braces 94 so as to provide a channelopening 112 into which extends the conveyor assembly 146. Upper andlower flange means 114 and 116 provided on the horizontal support bracesserve to support the conveyor assembly 146.

The conveyor assembly 146 is comprised of two spaced frame members 148and 150, interconnected by cross support 152, end plate 154 and back andfront plates 156 and 158. Support rollers 160 are journaled in the sidesof the frame members 148 and and engage the upper and lower flange means114, 116 to support and allow free lateral movement of the conveyorassembly 146 within the channel opening 112. The frame member 150 hasfour rollers journaled therein while the frame member 148 has only twosince frame member 150 will necessarily have to support a greater Weightthan member 148, as described hereinbelow. An axial air motor 162 isattached to the inner surface of the frame member 150 with one endconnected to a push plate 164 and the other end connected to the endplate 95 of the carriage assembly 90. The air motor 162 serves thepurpose of extending the conveyor assembly 146 outward toward the liningof the ladle or retracting it inward into the carriage assembly 90.

Two chains 166, provided between the frame members 148 and 150, serve asa conveyor to deliver bricks to the front end of the conveyor assembly146. The chains 166 are mounted on two sets of sprockets 168, 174, therear sprockets 168 being interconnected by a common shaft 172 journaledin support on the rear plate 156 and the front sprockets 174 beinginterconnected by common shaft 175 journaled in support 176 attached tothe cross support 152. The chains 166 are driven, in one direction only,by a conveyor indexing means 178 which is best seen in FIG. 5. Theindexing means 178 comprises a oneway friction clutch sprocket 182having an outer sprocket 184 with inner cam surfaces 190, an innercylinder 186 mounted on the common shaft 172 of the rear sprockets 168and a plurality of balls 188 located therebetween. A forward indexingsprocket 181 and an axial air motor 192 with piston rod 194 are mountedto a forward sprocket mount attached to frame member 148. The piston rod194 has attached thereto a chain connector 198 which in turn isconnected to the ends of a chain 196 passing over the forward indexingsprocket 18R and the one-way friction clutch sprocket 182, Extension ofthe piston rod 194 will effect a clockwise rotation of the outersprocket 184 which will cause the balls 188 to become tightly engagedbetween the cam surfaces and the inner cylinder 186 so that the innercylinder 186, and in turn the shaft 172, will rotate clockwise. Thisaction causes the chains 166 to move bricks forward toward the front ofthe conveyor assembly 146. Upon retraction of the piston rod 194,however, the outer sprocket 184 rotates counterclockwise and the balls188 disengage the inner cylinder 186, thereby imparting nocounterclockwise rotation to the common shaft 172. Instead, the chains166 remain stationary.

Located in the forward portion of the conveyor assembly 146 are threedevices for placing and properly positioning the bricks in the wall ofthe lining 28 as they are delivered along the chains 166: a conveyorpositioning 264. The conveyor positioning mechanism 200, as best shownin FIGS. 4, 10, 11 and 12, serves a dual function of orienting theextension of the conveyor assembly 146 and also the height of the systemrelative to the lining of the ladle. A wheel holder 202 is attached tothe conveyor assembly 146 and a dogleg connection by a pin 204 so as toallow pivotal movement of the wheel holder 202 thereabout. A support arm210, pin connected to the wheel holder 202 by pivot pin 212, hasjournaled in its distal end a conveyor extension wheel 208 for ridingalong the interior surface of the lining 28. The conveyor extensionwheel 208 controls actuation of the conveyor extending motor 162 so asto maintain a constant outward force against the interior of the ladleas bricks are being laid in place. Adjustment of the orientation of theconveyor extension wheel 208 is controlled by a pin 215 on support arm210 passing through an adjusting slot 214 in the wheel holder 202 andheld in place by a nut 216. A support cam follower wheel 206 isjournaled in the front face of the wheel holder 202 for riding along thetop row of bricks 144 in the lining 28 to control adjustment of theheight of the carriage assembly [96] 90. This is accomplished by meansof a pressure regulator mounted in housing 220 on frame member 150. Apusher block 230 having a regulator plunger 232 adapted to enter theregulator is threaded on a screw 228 attached to the rear support plate218 of the wheel holder 202. As the cam follower wheel 206 rides on thelining 28, the wheel holder will pivot about pin 204 to force theplunger [236] 232 into the regulator causing the air hoist 78 to actuateand raise the carriage assembly 90. A spring 222 shown in FIG. 4 isattached between a stop 226 and the support plate 218 to bias the wheelholder outward to force the plunger [236] 232 out of the regulator,thereby causing the air hoist to stop. Generally the spring force issufiicient to allow the cam follower wheel 206 to support about 5% ofthe weight of the carriage assembly 90. Thus it is apparent that anextra set of rollers 160 are necessary for supporting frame member 150in the carriage assembly 90.

The brick pusher 236 as best shown in FIGS. 7 and 10-12 is attached tothe other frame member 148 by means of an upright mounting plate 239which supports a rotary air actuator 238 with a substantially verticallyextending shaft 240. The shaft 240 has attached thereto at its lower enda linkage system comprised of a drive arm 242 having a drive armextension 244 pinned at its distal end by pin 243. A drive arm wheelholder 246 having a drive wheel 2S0 pinned thereto by pin 252 isintegrally attached at an angle to the drive arm extension 244 such thatthe wheel 250 will rotate in a plane parallel to the upper surface ofthe lining 28. A linkage arm 248 pinned to the air motor 238 by pivotpin 247 and pinned to the drive arm extension 244 by pivot pin 249controls the relative motion of the arm 244. As can be seen in thesequential views of FIGS. 10-12 as the shaft 240 is rotated in acounterclockwise rotation the drive wheel 250 travels along a fixed pathto engage the lastly laid brick and push it into place in the lining 28.

Operation of the brick pusher 236 is controlled by two limit switches257 and 261 positioned on a mounting plate 256 and the top surface ofthe air motor 238 respectively. A shaft block 154 attached to shaft 240has adjustably positioned thereon two actuating members 258 and 262.Upon actuation of the air motor 238, the shaft 240 will rotate in acounterclockwise motion, forcing the lastly laid brick 144 against thenext to lastly laid brick in the lining 28 until the forward limitswitch 261 is actuated by the plate 262. A signal will then be sent toreverse the motion of the shaft 240 to return the brick pusher to itsretracted position, the operation of the air motor 238 ceasing when theblock 258 actuates the return limit switch 257.

The brick gripper 264 for placing a brick 144 in the lining 28 ispositioned on two base pads 270 on the front of the front plate 158, andcomprises an air motor 266 which rotates a shaft 268 extending outwardfrom both sides thereof as best seen in FIGS. 6 and 10-12. Two spacedarms 272 and 282 are attached to the protruding ends of the shaft 268.Swing arm 272 is attached to the shaft 268 by means of two spacedflanges 274 engaging a block 276 rigidly fixed to the shaft 268 and apivot pin 278 passing therethrough. The distal end of the swing arm 272is provided with a gripping pivot point 280 for gripping one end of thebrick 144 and allowing the brick to rotate thereabout. The positioningarm 282 is rigidly fixed to the shaft [266] 268 so as to only rotatetherewith. The distal end of the positioning arm 282 is provided with arotating gripper 284 and a sprocket 288 interconnected by a shaft 286journaled in the arm 282. A clamping axial air motor 308 is pinconnected to the positioning arm 282 by pin 312, and has a piston rod310 connected to the swing arm 272 by pivot pin 314. Retraction andextension of the piston rod within air motor 308 will cause the swingarm 272 to pivot about the pin 278 to grip or release, respectively, abrick 144 between the gripping point 280 and the rotating gripper 284.

As best shown in FIGS. 6, 7 and 10, a fixed sprocket 290 is rotatablymounted on a shaft 291 which is adjustably fixed within a slot 293 in amounting bracket 292 aflixed to the front plate 158 in spaced relationfrom the air motor 266. The vertical elevation of the shaft 291 issubstantially the same as that of the shaft 268 of the air motor 266.Positioned on the rear of the mounting bracket 292 is an axial air motor294 with a piston rod 296 extending outward therefrom toward the fixedsprocket 290. A chain 298 is mounted around a roller 302 journaled inthe side of the positioning arm 282, and the two sprockets 288 and 290,one end of the chain being mounted to the piston rod 296 and the otherend being fixed to a spring 300 attached to the side of the positioningarm 282 by pin 304.

The bricks 144 are delivered in what is termed an upright position lyingon a longitudinal edge to the front of the conveyor assembly 146 wherethe brick gripper 264 grasps the bricks and translates them to the wallof the ladle 22 to form the lining 28 thereof. The bricks must bereoriented from the upright position to a horizontal position since thebricks of the lining 28 lie on one side wall surface with one of thelongitudinal edges abutting the safety lining 26 and the otherlongitudinal edge facing inward toward the center of the ladle. Aspreviously noted, the bricks are standard refractory bricks generallydescribed in US. Pat. 3,140,333 with one of the longitudinal edges beinglonger than the other. Normally, in a circular ladle, the longer of thetwo longitudinal edges is placed against the safety lining 26 so thatsuccessive bricks in the lining naturally are or bend to conform to thecircular surface of the ladle. Often, however, the size of the ladlesused in steel shops is increased by making the ladles elliptical infashion with flat spots or regions on the circumference of the ladle. Inthis situation, it is necessary along the fiat region to alternatelyreverse the orientation of the bricks so that the short longitudinaledge is alternately placed against the ladle safety lining 26 to form astraight region of lining. This is shown at flat region 29 on FIG. 3,the S denoting a short longitudinal edge and L" denoting a longlongitudinal edge. It is this dual reorientation of the bricks withwhich the chain 288 and sprockets 288, 290 are concerned, the operationof which is best seen in FIGS. 8A and 8B.

The center of the fixed sprocket 290 is positioned behind the pivotpoint of the gripper arm 282 so that rotation of the arm 282 will causea change in the distance along the path of the chain 298 between the endof the piston rod 296 and the sprocket 288 on the arm 282. The spring300 connected to the end of the chain 298 either extends or compressesto accommodate this change in distance and in turn causes the sprocket288 to rotate relative to the arm 282. For rotation of the arm 282 fromposition A to position C in FIG. 8A, the distance becomes less and thespring 300 compresses to pull the chain 298 around the sprocket 288thereby causing a clockwise rotation of the sprocket and brick relativeto the arm 282. For example, in position A, the arm 282 is oriented atan angle of [26- /2 26 /2 and picks up a brick [244] I44 lying on itsshort longitudinal edge (denoted by S). The initial length of spring 300is d and the center of the fixed sprocket is spaced at distance p behindthe pivot point of the arm 282. When the rotary air motor 266 isactuated, the arm 282 rotates counterclockwise 159 through position B toposition C where the bricks 144 are released, the arm 282 being [5-/: '15% below the horizontal, and

the brick 144 having rotated clockwise [63 /2 63 /2 so that it isroughly parallel to the top surface of the lining 28. The spring 300 hascompressed to a length d The distance "p between the center of thesprocket 290 and the pivot axis of the arm 282 depends on the size ofthe sprockets 288 and 290 and the amount of rotation of the arm 282 andmay be determined empirically in order to elfectuate the desiredrotation of the brick 144.

For the situation where the brick 144 is to be laid in the lining 28 ina reverse orientation, (i.e. the short longitudinal edge abutting thesafety lining 26) the piston rod 296 of the air cylinder 294 isretracted to rotate the brick 144 counterclockwise during rotation ofthe arm 282 by the air motor 266. Using the same example as above forFIG. 8A, the brick 144 is initially grasped when the arm 282 is inposition A with the spring 300 having a length 1 and the piston rod 296extended fully. However, as the arm 282 is rotated from position Athrough B to C, the piston rod 286 is retracted a distance r, causingthe brick 144 to rotate counterclockwise [l16- /z 116 /2 relative to thearm 282 such that the short longitudinal edge is adjacent the lining 26,In this situation, the spring 300 stretches from d in position A to d;,in position C. Again the distances "p and r are dependent on the size ofthe sprockets 288, 290 and the amount of rotation of the arm 282 and maybe determined empirically.

ill

Of course it should be understood that there are other ways of combiningthe spring 300, the chain 298, and the two sprockets 288, 290 toproperly reorient the brick 144 before it is placed in the lining 28 ofthe ladle 22. This may be accomplished simply by wrapping the chain 298in the opposite direction around the sprocket 288, that is, firstpassing the chain 298 underneath and then around the top of the sprocket288 to the spring 300. In this situation the spring 300 would stretchand the sprocket 288 would rotate clockwise during the rotation of thearm 282 for laying both a normal oriented and a reverse oriented brick144. Or the size of the sprockets 288, 290 could be varied and theseparation between the center of the fixed sprocket 290 and the centerof rotation of the arm varied, or even the position of the fixedsprocket 290 could be changed. The only thing necessary in making thesechanges is to ensure that it is possible to effectuate two differentamounts of angular rotation of brick 144 as the arm 282 is rotated fromposi tion A (picking brick up) to position C (releasing brick).

Also provided on the front plate 158 of the conveyor assembly areseveral mechanisms for controlling the operation of the brick layingmachine 20. As shown in FIGS. 6 and 7, an arm stop slide 340 isadjustably positioned along a bracket 342 by means of a screw 344. Anupward protruding member 341 is provided on the arm stop slide 340 forcontrolling the height of the gripper arms 272, 282 when picking up abrick 144. Forward motion of the arms 272, 282 is controlled by a limitswitch 306 which in the preferred embodiment in FIG. 6 is shown to beattached to the front of the air motor 266. Upon actuation of limitswitch 306, the arms 272, 282 stop rotating and the brick 144 heldtherebetween is released,

with the arms then returning to pick up another brick. The advancementof the bricks 144 along the chains 166 is controlled by a brick limitswitch 346 attached to a bracket 348 adjustably locatable on the frontsprocket support 176 by means of a screw 350 as shown in FIGS. 7 and 10.Upon actuation of the limit switch [348,] 346, the bricks are stoppedand remain stationary until the forwardmost brick is picked up by thegripper 264.

A brick aligner mechanism 316 for ensuring alignment of the bricks 144on the conveyor chains 166 comprises an axial air motor 318 adjustablymounted on a bracket 320, positioned on the frame member as shown inFIGS. 6, 7, 9 and 10. The axial air motor 318 has a piston rod 322 tothe end of which is attached a disc 324. As the bricks 144 are advancedalong the chain 166, the air cylinder 318 is periodically actuated toextend the disc 324 to push the bricks transversely on the chain 166thereby aligning them for pickup by the gripper mechanism 264.

Also positioned on the conveyor assembly 146 is a mortar bucket 326supported by a cross support 330 connected to two uprights 328 mountedon frame members 148 and 150 as shown in FIGS. 1, 2 and 7. The mortarbucket 326 contains a slurry type mortar delivered to the lining 28 bygravity in a flexible hose 334, one end of which is connected to thelower nozzle 332 of the mortar bucket 326 and the other end of which ispositioned in a hose support 338 extending outward from the air motor238. A control valve or clamp means 336 having an actuator 337 isprovided for controlling the flow of mortar to the lining. It should benoted that the use of mortar is not necessary due to the interlockingaction of the bricks 144, but is merely shown for the situation where itis desired to supplement the holding of the bricks in place in thelining.

The operation of the automated bricklaying device 20 is as follows. Theladle 22 is cleaned of excessive slag and dirt accumulation andinspection and repair of the bottom and the safety lining 26 isundertaken in the conventional manner. The bottom brick lining and wellblock are laid up as is the skew brick ring which is comprised of onetapered starter set 27 and several spiraling courses of semi-universalrefractory brick 144, also in the conventional manner. The taperedstarter set is necessary to provide that the working lining 28 is builtup by spiraling courses.

The automated bricklaying device is then lowered into the ladle, eitheras a whole unit or in components as previously noted and leveled byscrew jacks 40 on turntable 30 to rest on the bottom brick lining. Thebricklaying machine may then be connected to a power source and operatedin a manner to be described hereinbelow.

As previously noted, the bricklaying device 20 in the preferredembodiment is a totally air operated device as opposed to, for example,an electrically operated device. This is merely a matter of preference,depending on the type of shop in which the bricklaying machine will beused and the capabilities thereof, and it makes no major difference whattype of power source is employed. It is conventional in most steel shopsto use air as a source of power to operate various devices for operationtherein and, as such, air was initially chosen to supply the power foroperation.

The particular control diagram 400 for the preferred embodiment isdepicted diagrammatically in FIGS. 14A and 14B. As a key to aid inunderstanding the diagrammatic representation, the following should benoted. The numbers 412 and 414 on FIG. 14A represent typical main airsupply lines for operating the various air motors and air cylinders ofthe bricklaying machine 20; the numbers 428 and 442 on FIG. 14Arepresent typical pilot lines for switching control valves from oneposition to another; the number 476 on FIG. 14A represents a typicalcheck valve which permits air to liow in the line 478 in one direction(to the right) and prohibits air flow in the other direction (to theleft); the number 594 of 14B represents a typical adjustable flowcontrol valve to control the flow of air therethrough; the number 474 onFIG. 14A represents a typical pressure regulator which controls theamount of air pressure delivered to the lefthand portion of the line414; the number 424 on FIG. 14A represents a typical mechanicallyactuated control valve with a spring return which will return to itsnormal position upon release of the operator; the number 518 on FIG. 148represents a typical air actuated control valve whose position ischanged by providing air to one of the chambers A" or B, the valveremaining in that position until air is provided to the other of thechambers; and the numbers 408 on FIG. 14A and 538 on FIG. 14B representtypical manually actuated control valves whose position is changedmanually and maintained thereat by detents.

With the above brief description of the diagrammatic representation inFIGS. 14A and 14B, the operation of the bricklaying machine 20 is asfollows. The main supply of air to the machine is provided from acompressor (not shown) by the supply line 402, a filter 404 andlubricator 406 being provided in the line 402 so that the air to thesystem is clean and lubricated. Air is supplied by branch line 416 tothe control valve 418 to operate the air hoist 130 of the boom mechanism118 independent of the rest of the system. The control valve 418 is athree-position valve for controlling the air motor 130 to raise, tolower, or to stop the cable 131. Actuator 419U shifts the valve 418 tosupply air from line 416 to line 420 to raise the cable 131, with air indown line 422 exhausting through vent line 421 while the actuator 419Dshifts the valve 418 to the other side so that air is delivered to thedown side of the air motor 130 to lower the cable 131.

The remainder of the operation of the bricklaying machine is controlledby the three-position manually-actuated valve 408 which, in FIG. 14A, isshown in a neutral position sending no air to the system. Initially thevalve 408 is placed in the manual position so that air will be providedfrom the branch line 410 to the main manual control line 412, and theair in the automatic line 414 will exhaust to the atmosphere throughvent line 413. The main hoist valve 434, as with the valve 408, is athreeposition valve to which air is delivered via lines 412, 415, 430and 436 to control the air hoist 78 for raising and lowering thecarriage platform assembly on the elevator frame assembly 64. Thecontrol system is also provided with a conventional spring biased brake450 and a slack cable limit switch 426 for restricting opera tion of theair hoist 78. The brake 450 automatically locks the air hoist 78 inplace if no air is sent to it along pilot line 452 and the slack cablelimit switch releases the air in line 429, 452 if the cable 81 of thehoist 78 is slack, the slack position being shown in FIG. 14A. If thecable 81 is not slack, the valve 426 is depressed so that no air will bereleased from line 429 as described hereinafter. Pilot air is dclieveredfor manual operation by pilot lines 442 and 446 joined to the air hoistup and down lines 438 and 440 respectively. Check valves 444 and 448 arepositioned in pilot lines 442, 446 to prevent a reverse flow from onepilot line to the other, which would prevent release of the brake 450.

Lowering of the cable 86 of the hoist 78 and thus the carriage assembly90, is accomplished by placing valve 434 in the down position so thatair will be provided from line 436 through line 440 to both the brake450 and the down" side of the air hoist 78. Air is released from the upside of the motor 78 through the up line 438 to vent line 439. Thecarriage assembly 90 is lowered until it is at the approximate heightnecessary to start laying bricks in the lining, in which case the valve434 is placed back in its neutral position (see FIG. 4). Next, theconveyor assembly 146 is extended from beneath the carriage assembly 90so that the conveyor extension wheel 208 rides against the inner surfaceof the lastly laid bricks in the lining 28. The conveyor extension valve464 is placed in the out position and air is delivered to the extensionair motor 162 by lines 412, 415, 458 and 466. A pressure regulator 460in the line 458 controls the amount of air pressure in line 458 to theright of the regulator 460 and as such the amount of pressure delieveredto the extension motor 162. Normally the regulator 460 is set so as toprovide a sufiicient force on the conveyor extension wheel 208 toproperly set the bricks 144 in the lining 28 against the safety lining26, this occurring as the conveyor assembly [90] 146 revolves around thecircumference of the ladle, notwithstanding the fact that the turntableassembly is not positioned in the center of the ladle andnotwithstanding the fact that the ladle may be elliptical. As air isdelivered to the extension motor 162 by line 466, air in the in line 468is controllably released to the atmosphere through the vent line 470 andflow control valve 472 situated therein.

After the conveyor assembly 146 has been properly positioned against thelining 28, the carriage assembly is again lowered until the cam followerwheel 206 rests on the top surface of the lining 28. A manual overridevalve 424 has been provided where it is desired to release the brake 450when the cable 86 on the air hoist 78 is slack, such as might occur ifthe hoist 78 were lowered too far when the cam followed wheel 206 restedon the lining 28. When the valve 424 is actuated, air passes from branchline 423 to pilot line 428 to actuate the slack cable limit switch 426so that air in line 429 is not released to the atmosphere through ventline 427, but instead passes to release the brake 450. Although thevalve 426 is positioned to pass air from line 429 through line 484 toline 480, no such passage occurs due to the check valve 482 beingsituated in line 480. Normally the manual override valve 424 ispositioned so that any air in pilot line 428 is released to theatmosphere throuhg vent line 425.

After the carriage assembly 90 is properly positioned within the ladlethe main control valve 408 is shifted to provide air to the automaticline 414 and drain air in the manual line 412 through vent line 413. Theair pressure in the automatic line 414 is controlled by the pressureregulator 474, a bypass line 478 with check valve 476 being provided inparallel to allow drainage of the automatic line 414 when the valve 408is in a manual position. For automatic operation, the main hoist valve434 is placed in an up" position and a pilot line 484 from line 480provides air to release the brake 450 if the cable 86 is not slack. Apressure regulator 488 in line 480, controlled by the conveyorpositioning mechanism 200 as described hereinabove, serves to provideair to the hoist 78. If the plunger 232 (see FIG. 4) is not depressedinto the regulator due to the force exerted by spring 222 being greaterthan that exerted on the cam follower wheel 206, then no air is allowedto pass through the regulator to line 436 to actuate the hoist 78 toraise the carriage assembly 90. Instead, since the brake 450 isreleased, the carriage assembly 90, and thus the conveyor assembly 146,will start to move downward along the elevator frame assembly 64. As theforce on the cam follower wheel 206 forces the plunger into theregulator 488, air from line 480 is allowed to pass through theregulator to the main hoist valve 434 to actuate the hoist mechanism 78.As the hoist mechanism is actuated, the conveyor assembly 146 is raised,relieving the weight which the cam wheel 206 supports until the spring222 forces the regulator plunger 232 out of the regulator 488 to stopthe fiow of air therethrough. The conveyor assembly 146 continues tooscillate, falling downward since the brake 450 is released and risingsince the plunger 232 is inserted, until a balance of forces ismaintained in which the conveyor assembly rests at the proper height.The air hoist 78 is periodically actuated as the cam wheel 206 rides onthe spiraling courses of bricks built up in the lining 28 and thus thistype of mechanism provides a self-regulating control of the height ofthe carriage assembly 90 in the ladle 22. Alternatively, a limit switchcould be used in place of the pressure regulator 488 if precisemodulating control of the height of the platform is not required.

Air from the automatic line 414 is provided to the extension motor 162by branch line 492 which connects to the line 458, the operation of theextension motor 162 being as previously described for manual operationwith the valve 464 in an out position. Check valves 490, 432, 494, and456 are provided in branch lines 480, 430, 492 and 415 respectively sothat the air in these lines will not be released to the atmosphereduring either automatic operation or manual operation. These checkvalves are necessary since both the automatic and manual lines arecommonly connected to the branch lines 436 of the main hoist valve 434and 458 of the main conveyor extension valve 464.

With the conveyor assembly 146 properly positioned relative to thecircumference of the ladle 22 and ready for operation to lay bricks. theboom mechanism 118 is operated to place bricks 144 on the conveyorchains 166. The stop-start switch 538 is then placed in a start position(as shown in FIG. 14B allowing air to pass between pilot lines 532 and540) and the manual operator 500 on the front index switch 498 isactuated. Air passes from line 508 through the valve 498 to the pilotline 510 into chamber B" of conveyor indexing valve 518 to switch valve518 so that air passes from branch line 520 to return line 524 toretract the piston rod 194 of the indexing motor 192, air from the otherside of the motor 192 being exhausted through extension line 522 andvent line 519. Pilot air from line 510 is also provided to chamber A" ofthe brick aligner valve 544 by line 516 so that air from line 548 passesthrough valve 544 to line 550 to extend the piston rod 322 of the brickaligner motor 318 to align the bricks 144 on the chains 166. The pistonrod 194 of the conveyor indexing motor 192 is retracted until the rodactuator 504 engages the operator of the rear indexing switch 530 toallow pilot air in line 528 to pass through valve 530 into pilot line532. Pilot air is initially delivered to pilot line 528 from pilot line508 via line 526 which passes through the brick limit switch 346 as longas a brick 144 does not engage the operator of the valve 346. The air inline 532 passes through the stop-start switch 538 into chamber A toswitch valve 518 to extend the piston rod 194 of the conveyor indexingmotor 192. At the same time, pilot air in line 532 is delivered by line536 to chamber B of the brick aligner valve 544 causing the valve tochange positions to retract the piston rod 322 of the brick alignercylinder 318. The piston rod 194 is extended until the rod actuator 504engages the operator 502 of the valve 498 to return the rod aspreviously described by manual actuation of operator 500.

This sequence of operation of advancing bricks 144 along the length ofthe conveyor assembly 146 continues until a brick 144 actuates theoperator of the brick limit switch 346 to switch the valve 346 to passair therethrough from line 526 to line 556. Pilot air is then deliveredby line 558 into a chamber in valve 498 to actuate the valve 498 forreturning the piston rod 194 in the indexing cylinder 192. However, whenthe rod actuator 504 engages the operator of valve 530, the valve 518will not switch to extend the rod 194 until the brick 144 is removed torelease the brick limit switch 346 since air is not then being deliveredto line 528. As thus far described, each of the valves and limitswitches 498, 530 and 346 are provided with vent lines 512, 532 and 554respectively so that any air in the connecting lines is released to theatmosphere. This is necessary since the air in either chamber A or B ofvalves 518 and 544, if not released, would oppose the air sent to theother of the chambers and would thus prevent switching of the valves 518and 544.

After a brick 144 has actuated the valve 346, the air in line 556 passesto valve [261] 257 of the brick pusher mechanism 236 which is actuatedto allow air into line 564 only when the brick pusher mechanism is in areturn position. The air in line 564 then passes to chamber 3" of thegripper control valve 568 to switch the valve to allow air to passthcrethrough from line 506 to line 570. The air in chamber A" of valve568 is exhausted through vent line 601 via lines 612, 602. From line570, the air is delivered to the clamp cylinder 308 by line 580 whichhas a pressure regulator 586 positioned therein for controlling theclamping force applied by the motor 308 in order not to crush or crackthe bricks grasped by the arms 272, 282. A bypass line 582 with checkvalve 584 is connected in parallel across the pressure regulator 586 toprovide a quick exhaust of air from the clamp motor 308 when the signalis given to release the brick. Line 570 also delivers an to the rotaryair motor 266 by line 572 to take the brick 144 from the chains 166 andplace it in the wall of the ladle 22, the motion being clockwise asshown in FIG. 14B. A check valve 576 in bypass line 574 is connected inparallel across a flow control valve 578 in line 572, the check valve576 passing air quickly to the air motor 266 while preventmg back flowtherefrom and the flow control valve 578 controlling the air releasedfrom the air motor 266 during the return thereof to pick up anotherbrick.

The air in line 570 also passes through the valve 354 located on thebase of the connecting couple 68 of the elevator frame assembly 64 tocontrol the operation of the sprockets 288, 290 and chain 298 on thegripper arm 282. If the operator on the valve 354 has not been actuated,then an is delivered to line 588 to keep the piston rod extended in theair motor 294. Actuation of the operator on the valve 354 can best beseen in FIG. 13 wherein the upper platen 34 has rotated relative to thelower platen 32 such that the limit switch 354 is located adjacent tothe cam trippers 356 supported by supports 358 from the bottom platen32. As the upper platen 34 continues to rotate relative to the lowerplaten 32, the operator of the limit switch 354 will be depressed by thecam tripper 356 thus causing the valve 354 (see FIG. 14B) to shiftpositions so that air in line 570 is delivered to line 590. The air inline 590 passes through a flow control valve 594 to the air cylinder 294to controllably retract the piston rod 296 as the gripper arms 272, 282rotate to lay a brick in the lining 28. A bypass line 596 with checkvalve 598 is provided in parallel to control valve 594 so that air willbe exhausted quickly through line 590 to vent line 592 when the valve354 is not actuated by the cam tripper 356.

As the gripper arms 272, 282 rotate to deliver the brick 144 to thecircumference of the ladle 22, the arm 282 engages and actuates a limitswitch 306 as best seen in FIG. 6. Referring again to FIG. 14B, when thelimit switch 306 is actuated, air is provided from pilot line 600 toline 602 and, in turn, to lines 612 and 604. Pilot air in line 604enters chamber A of valve 566 to shift the valve to release the air inchamber B of valve 568 through vent line 567. and pilot air in line 412enters chamber A of valve 568 to shift the valve 568 so air is suppliedfrom line 506 to line 614. Flow control valve 606 positioned in line 604restricts the release of air from chamber A of valve 566 in order toprovide a time delay before air may again be delivered to chamber B ofvalve 568 to cause actuation of the motor 266 to lay a brick. Bypassline 608 with check valve 610 is provided in parallel to the flowcontrol valve 606 in order to effect a quick shifting of valve 566. Theair in line 614 is passed i to extend the piston rod of the clamp motor308 to release the brick hcld thereby and is also sent, via branch line620, to return the brick gripper arms 272, 282 to pick up another brick144. A bypass line 624 with check valve 626 is connected in parallelfashion across the flow control valve 622 in line 620 so that air willbe quickly sent to the air motor 266 to return the arms 272, 2.32, andwill be released through the flow control valve 622 upon actuation ofthe air motor 266 to lay a brick. The

pressure regulator 618 in line 614 is set so that only a 3 small amountof air, which is all that is needed to client the return of the brickgripper and release of the brick,

is delivered to the air motor 266 and the clamp motor 308. A check valve616 is placed in line 614 so as to allow a build-up of air on the returnside of the motor 266 when laying a brick in order that the brick is notslammed into the lining. When the valve 568 is in the position shown inFIG. 14B. air in line 570 is released to the atmosphere by vent line569.

Pilot line 602 also delivers air to chamber A of the brick pusher valve628 to switch the valve to allow air to pass from line 630 into line 634to the push side of the air motor 238, thus actuating the brick pushermechanism 236 to push the brick 144 into place against the astly laidbrick in the lining 28. A pressure regulator 636 is provided in line 634in order that the force of the brick pusher 236 does not become toogreat so as to crush bricks. Air in the return side of the motor 233 isquickly exhausted through vent line 629. As the brick pusher 236 isactuated, air is also sent to actuate the turntable air motor 60. Pilotline 644 continuously delivers air through the normally unactuatedcontrol valve 648 to line 652 into chamber A of turntable control valve654 to force the valve into position to allow air to pass from line 662into line 664, thereby actuating air motor 60 to turn the turntable 30clockwise. The valve 654 is a three-position air actuated, spring biasedvalve such that when air is not being continuously provided to chamber Aor B, then the spring bias will force the valve 654 into a neutralposition as shown in FIG. 1413. The brick pusher mechanism 236 is morequickly actuated than the turntable air motor 60 since a flow controlvalve 670 is positioned in line 666 to controllably exhaust the air inthe other side of the air motor 60 through the vent line 668. A bypassline 672 with check valve 674 is connected in parallel across the fiowcontrol valve 670 to allow air to pass quickly in line 666 to thecounterclockwise rotation side of the air motor 60 if the valve [668]654 were in position to deliver air from line 662 to line 666.

The brick pusher 236 continues to rotate, due to actuation of both theair motors 238 and 60, until the limit switch [257] 26] is actuated,thus indicating occurrence of a predetermined amount of rotation whichis sufiicient to allow placement of the next brick in the lining 28.When this occurs, valve [257] 26] shifts to allow air in line 638 topass to line 642 into chamber B of valve 628 to switch the valve toreturn the brick pusher 236 to its return position. The air in chamber Ais exhausted through vent line 601 of valve 306, the valve 306 being inits unactuatcd state since the gripper arms on the brick gripper 264have returned to their return position. When the brick pusher valve 628changes positions upon air entering chamber B, the air in line 634, andthus in line 644, is released to the atmosphere to the vent line 629.The valve 654 then returns to its neutral position due to the springbias and also due to momentarily air being sent to chamber 13" by pilotline 646.

During operation of the brick gripper 264 and the operation of the brickpusher 236, the conveyor indexing mechanism 192 has been actuated (dueto release of valve 346 when the brick gripper 264 picked up the brick144) to deliver the next to be laid brick along the conveyor chains 166,thus actuating the valve 346 and sending air from line 526 to line 556.When the brick pusher 236 returns, valve [261] 257 will be actuated andair will be delivered from line 556 to line 564 and another brick willbe laid in place in the manner described above.

When initially orienting the conveyor assembly 146 relative to thecircumference of the indie 22, it may be necessary to actuate air motor60 in order to turn the conveyor assembly. This is accomplished byplacing the main control valve 408 in the manual position and using pushbutton valves 648 and 656. IF the air motor 60 is to be operated to turnthe turntable 30 clockwise, valve 648 is continually depressed todeliver air from lines 680, 676 to chamber A" of valve 654. Theoperation for counterclockwise rotation of the turntable 34 isaccomplished by actuation of valve 656 in a similar manner to that donefor clockwise rotation. Check valves 68?. and 684 are provided in lines546 and [415] 412 respectively so that air will not be fed into themanual line during automatic operation or fed into the automatic lineduring manual operation.

From the foregoing it is apparent that there is herein provided anautomated bricklaying device 20 which permits the rapid buildup of thespiraling courses of refractory brick 144 necessary to form the workinglining 28 of a metal pouring ladle 22. The shell of the ladle 22provides a circumferential guidance while the spiraling brick coursesthemselves provide the necessary height guidance so that the bricks areproperly placed to form the working lining 28. A conveyor indexingmechanism to the front of a conveyor assembly 146 wherein a brickgripper mechanism 264 grasps the bricks one at a time and lays them inthe lining 28 of the ladle 22. A brick pusher mechanism 236 and aconveyor extension where] 208 attached to the front of the conveyorassembly 146 serves to firmly secure and set each brick against thepreviously laid brick and causes actuation of a turntable motor 60 toindex the device 20 to the proper posilion for laying the next brick in.the lining. During operation of the pushing cycle and indexing cycle, itit is desirous mortar may be provided to be placed in the working liningso as to ensure a proper seating and holding of the bricks within theladle.

It will be understood that various changes in the details, materials andarrangements of parts which have been herein described and illustratedin order to explain the matter of the invention may be made by thoseskilled in the art within the principle and scope of the invention asexpressed in the appended claims.

What is claimed is:

1. An automated bricklsying device for laying out the brick lining of a.vessel, the device comprising:

a delivery means for delivering a series of bricks in 15 turn to thecircumference of the vessel to be set as the lining thereof;

a brick positioning means associated with said delivery mcans for bothct'rcnmfcrentiolly and laterally positioning and firmly setting eachbrick in turn in the lining as it is delivered to the circumference ofthe vessel;

a supporting means for supporting said delivery means and said brickpositioning means inside the vessel and for permitting. of said deliverymeans and said brick positioning means, longitudinal movement along.reciprocal lateral movement relative to and revolutional movement aboutan axis thereof positioned within and substantially parallel to the axisof the vessel to be lined;

an operating means for moving said delivery means and said brickpositioning means longitudinally along, laterally relative to andrevolutionally about said axis of said support means so as to positionsaid delivery means and said brick positioning means rela- B tive to thecircumference of the vessel; and [a] automatic control means forcontrollably operating said operating means [alter a brick has beenpositioned in place in the lining for properly positioning said deliverymeans and said brick positioning means] including means for stoppingsaid operating means when said delivery means and said brick positioningmeans are properly positioned for the placement of the next succeedingbrick in the lining. said means being responsive to the position of thelastly laid brick in the lining.

2. The apparatus of claim 1 wherein said support means includes anupright frame assembly mounted within the ladle, and a platform assemblycarried by said upright frame assembly for longitudinal movementtherealong, said delivery means being mounted to said platform assemblyfor reciprocal lateral movement relative thereto.

3. The apparatus of claim 2 wherein said support means further includesa turntable placed in the bottom of the vessel, said turntablecomprising a lower platen and an upper platen supported by said lowerplaten for rotational movement relative thereto, the axis of rotatiorbeing said axis of said support means, and wherein said upright frameassembly is mounted to said upper platen whereby, when said upper platenrotates relative to said lower platen. said delivery means revolvesabout said axis of rotation.

4. The apparatus of claim 3 wherein said operating means includes ahoist means for selectively raising and lowering said platform assemblyassembly and a reciprocating drive means for selectively extending andretracting said delivery means relative to said platform assembly.

5. The apparatus of claim 4 wherein said operating means furtherincludes a rotary actuating means for imparting rotary movement to saidupper platen of said turntable relative to said lower platen.

6. The apparatus of claim 5 wherein said automatic control meansincludes a first limit switch means for causing operation of said rotaryactuating means and wherein said means of said automatic control meansfor stopping said operating means is a second limit switch means forstopping operation of said rotary actuating means. said second switchmeans being actuated to stop said rotary actuating means after saidbrick positioning means has moved a predetermined distance relative tothe circumference of the vessel.

7. The apparatus of claim 6 wherein said first limit switch means isactuated to cause operation of said rotary actuating means after saidplacement means has placed a brick in the lining.

8. The apparatus of claim 4 wherein said control means includes avertical guidance means on said platform assembly, said verticalguidance means causing actuation along said upright frame 15 of saidhoist means so as to maintain a fixed vertical relation between saidplatform assembly and the built up lining.

9. The apparatus of claim 4 wherein said control means includes anextension guidance means on said delivery means, said extension guidancemeans actuating said reciprocating drive means so as to maintain a fixedrelation between said delivery means and the built up lining.

10. The apparatus of claim 1 wherein said delivery means is a conveyormeans having a conveyor indexing means for selectively advancing thebricks on said conveyor means to the circumference of the vessel.

11. The apparatus of claim 10 wherein said delivery means includes aplacement means for taking a brick from said conveyor means and placingit in the circumference of. the vessel.

12. The apparatus of claim 1 wherein said brick positioning meanscomprises a first means for pushing a brick delivered to thecircumference of the vessel into engagement with the previously laidbrick and a second means for pushing a brick delivered to thecircumference of the vessel into engagement with the interior wall ofthe vessel.

13. An automated bricklaying machine for laying out the refractory bricklining of a metal pouring ladle, the machine comprising:

an upright means extending into the ladle;

a mounting means for supporting said upright means for traversing aboutthe circumference of the ladle;

a platform means carried by said upright means for vertical movementtherealong;

means for selectively raising and lowering said platform means relativeto said upright means;

a delivery means on said platform means reciprocally laterally movablerelative thereto for delivering a series of refractory bricks in turn tothe circumference of the ladle to be set as the lining thereof;

a positioning and indexing means on said delivery means for properlypositioning each brick in turn in the lining while indexing saidplatform means to a proper position for placement of the next succeedingbrick in the lining; and

vertical guidance means on said [conveyor] delivery means for providingvertical elevational control of said platform means relative to thebuilt up lining.

14. The apparatus of claim 13 wherein said mounting means is a turntableplaced on the bottom of the ladle, said turntable comprising a lowerplaten and an upper platen supported by said [J lower platen forrotational movement relative thereto.

15. The apparatus of claim 14 wherein said upper platen is supported bymeans of a plurality of rollers journaled on the side of said lowerplaten and wherein said lower platen has a plurality of leveling screwsfor leveling said lower platen.

16. The apparatus of claim 15 wherein said turntable includes a gearring mounted to said lower platen; a pinion gear having a shaftjournaled in said upper platen and having teeth engaging teeth of saidgear ring; a sprocket means fixed to said shaft of said pinion gear; arotary actuating motor mounted to said upper platen; and a chain meansfor said sprocket means and said rotary actuating motor whereby, whensaid rotary actuating motor is actuated, said upper platen is rotatedrelative to said lower platen.

17. The apparatus of claim 16 wherein said positioning and indexingmeans includes a second means for pushing a brick in the lining intoengagement with the previously laid brick in the built up lining.

18. The apparatus of claim 17 wherein said second means is a brickpusher having a rotary actuating means; a wheel means; a linkage meansconnected at one end to said rotary actuating means and connected at theother end to said wheel means such that upon actuation of said rotaryactuating means said wheel means follows a fixed 17 path to push brickin the lining into engagement with the previously laid brick.

19. The apparatus of claim 18 wherein there is a com trol systemassociated with said brick pusher and said rotary actuating motor onsaid turntable for actuating said rotary actuating motor on saidturntable when said rotary [actuator] actuating means of said brickpusher is actuated.

20. The apparatus of claim 19 wherein said brick pusher includes a limitswitch means which, when actuated, stops said brick pusher from pushingand indicates that said platform means is in a proper position forplacement of the next succeeding brick in the lining.

21. The apparatus of claim 13 wherein said delivery means includes aconveyor means for advancing bricks thereon toward the circumference ofthe ladle and a placement means for taking bricks in said conveyor meansone at a time and placing them in turn in the lining.

22. The apparatus of claim 21 wherein said delivery means furtherincludes a conveyor indexing means having a one-way friction clutch anda reciprocating drive means whereby said conveyor means is advanced whensaid oneway friction clutch is driven in a first direction by saidreciprocating drive means and said conveyor means remains stationarywhen said one-way friction clutch is driven in a second direction bysaid reciprocating drive means.

23. The apparatus of claim 21 wherein said placement means is a brickgripper for transferring a brick in a first position on said conveyormeans to a second position in the lining.

24. The apparatus of claim 13 wherein said positioning and indexingmeans includes a first brick pushing means for laterally pushing a brickin the lining into engagement with the interior wall of the ladle.

25. The apparatus of claim 24 wherein said lateral brick pushing meansis an exterior wheel positioned on said delivery means.

26. The apparatus of claim 13 wherein said means for selectively raisingand lowering said platform means is a hoist motor positioned on saidupright means.

27. The apparatus of claim 26 wherein said vertical guidance means is awheel means carried by said delivery means which rides on the top of thebuilt up lining, said wheel means actuating said hoist means on saidupright means for maintaining a fixed vertical relation between saidplatform means and the built up lining.

28. The apparatus of claim 13 wherein said platform means includes ameans for picking up bricks resting on said platform means and placingthem on said delivery means.

29. In a bricklaying machine for lining a ladle with bricks having aconveyor means, a placement means having a pickup position and aplacement position, a brick positioning means having a return positionand a pushing position, and an apparatus positioning means, a controlsystem for controllably operating the machine to perform a series ofsequential operations comprising, in combination:

a first means for operating the conveyor means to deliver the bricks tothe placement means;

a second means for operating the placement means to place the bricks inthe lining of the ladle;

a third means for operating the brick positioning means to properlyposition the bricks in the lining;

a fourth means for operating the apparatus positioning means to indexthe conveyor means, the placement means and the brick positioning meansrelative to the circumference of the ladle;

a first switch means for controlling said first means such that whensaid first switch means is actuated, said first means is operable tocause said conveyor means to stop, said first switch means beingactuable whenever a brick on said conveyor means is in position forremoval therefrom by said placement means;

a second switch means for controlling said second means such that whensaid second switch means is actuated, said second means is operable tocause said placement means to pick up a brick from said conveyor meansand move said brick toward said ladle lining, said second switch meansbeing actuable whenever said first switch means is actuated and saidbrick positioning means is in a return position;

a third switch means for controlling said second means, said third meansand said fourth means such that when said third switch means isactuated, the following operations take place:

a. said second means is operable to cause said placement means to stop,to release the brick held thereby, and to return to its pickup position,

b. said third means is operable to cause said brick positioning means tomove towards said pushing position to properly position said brickreleased by said placement means in said ladle lining, and

c. said fourth means is operable to cause said apparatus positioningmeans to move said conveyor means, said placement means and said brickpositioning means relative to said circumference of said ladle, saidthird switch means being actuable when said placement means is in theplacement position to place said brick in said lining; and

a fourth switch means for controlling said third means and said fourthmeans such that when said fourth switch means is actuated the followingoperations take place:

a. said third means is operable to return said brick positioning meansto its return position, and

b. said fourth means is operable to cause said apparatus positioningmeans to stop, said fourth switch means being actuable when saidapparatus positioning means has indexed said conveyor means, saidplacement means and said brick positioning means to a proper positionfor placement of the next succeeding brick in the lining.

30. The apparatus of claim 29 wherein said first means is a conveyorindexing means including a one-way friction clutch for driving saidconveyor means in one direction only.

31. The apparatus of claim 30 wherein said conveyor indexing meansincludes a reciprocal drive motor having an advancing motion and aretraction motion, said reciprocal drive motor being controlled by twolimit switch means for causing advancing motion and for causingretraction motion.

32. The apparatus of claim 29 wherein there is a fifth means foroperating said placement means to place bricks in the lining in one oftwo different orientations and wherein there is a fifth limit switchmeans for controlling said fifth means.

33. The apparatus of claim 29 wherein said fourth means includes avertical drive means, a lateral drive means and a rotational drive means[whereby] and wherein said third and fourth limit switch means[controlling] control operation of said rotational drive means, saidvertical drive means and said lateral drive means [being controlled soas] to maintain a fixed vertical and lateral relation between [said] theconveyor means and the circumference of the ladle as said rotationaldrive means rotates the conveyor means, the placement means and thebrick positioning means.

34. The apparatus of claim 29 wherein said control system is a pneumaticcontrol system and wherein said first, second, third and fourth meansare pneumatic operating means and said first, second, third and fourthlimit switch means are pneumatic limit switches.

(References on following page)

